Clamp assembly for attaching panels to substrate

ABSTRACT

A quick and easy technology for attaching, and facilitating reconfiguration (detachment and reattachment) of, panels to walls that uses a clamp assembly including a base, a receptacle attached to the base and a clasp that fits into and attaches to the receptacle. The clasp has resilient arms and a head. Insertion of the resilient arms of the clasp into the receptacle draws the head towards the base, which produces a clamping action. Alternatively, the clamp assembly includes a channel having sidewalls attached to a base and at least one fastener having a blade-like shank and a head. The sidewalls converge so as to be more closely spaced together at the opening of the channel than at its base. The at least one fastener appears T-shaped in cross section, and is sized so that insertion of the blade-like shank into the channel widens the opening. Alternatively, the clamp assembly includes a first clamping piece and a second clamping piece configured to cooperatively engage each other. The first and second clamping pieces include the members of a reclosable fastener pair, such as hook and loop connector pair or strips of mushroom-shaped stems.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The invention is directed toward a clamping assembly, and moreparticularly toward a clamping assembly for attaching panels to asubstrate such as a wall.

BACKGROUND OF THE INVENTION

For some rooms in a building, it is desirable to control soundtransmission. Such rooms include home theaters, recording studios andoffices in which confidential conversations take place. In such anoffice, the control of sound transmission takes the form of soundproofing to prevent the escape of intelligible conversation from theroom. This is true to a lesser extent with the home theater or recordingstudio, where the emphasis is on controlling the sonic quality insidethe room.

An approach to control sound transmission is to attach acousticallysignificant panels, be they absorbers or diffusers, to the room'ssurfaces. Examples of such acoustically significant panels are disclosedin copending U.S. patent application Ser. No. 08/871,021, filed Jun. 6,1997, on behalf of McGrath et al. and entitled “Acoustical Room Panelingand Method of Installation,” the entire contents of which are herebyincorporated by reference.

To initially tune a home theater or a recording studio, the walls and/orceiling must, at first, be covered by the panels. Then, it is usuallynecessary to change at least a few panels from being acousticalabsorbers to acoustical dispersers/diffusers and/or vice-versa. Thisrequires removing the fasteners from the first panel and reinstallingthem through either the first panel after it has been reversed or anentirely different second panel.

Typically, the panels are attached using conventional fasteners, e.g.,drywall screws in rooms having walls formed of drywall attached tostuds. Drilling pilot holes in the panels for such screws or screwingthrough the panels causes minor damage to the panels. Screwing,unscrewing and rescrewing panels is time consuming and protracts theprocess of tuning a room.

Nor is this the last time that such an attaching/detaching process islikely to be required. If someone changes the furniture and/or windowtreatments in the home theatre, the room should be retuned. Suchredecoration is likely to occur a only few times, at most. In arecording studio, however, the need for retuning can arise daily, andpossibly more frequently. For example, if a recording studio is tunedfor vocal sessions on Monday, then it should be retuned for stringsessions on Tuesday, retuned for percussion sessions on Wednesday, etc.

Not all recording studios are permanently constructed. Temporaryrecording studios are becoming more prevalent. A musical group mightwish to record in an ancient castle or at a remote location because ofthe location's ambience. A temporary recording studio can significantlyimprove the quality of the recording. Important to the success of atemporary recording studio is its ease of assembly/disassembly. The needfor easy attachment/detachment of panels, as discussed above,contributes greatly to the ease of the temporary recording studio'sassembly/disassembly. Moreover, a temporary recording studio, onceassembled, is as likely to be reconfigured to accommodate differentrecording sessions as a permanently constructed recording studio.

SUMMARY OF THE INVENTION

The invention, among other things, represents a recognition that abetter technology for attaching/detaching panels to substrates (such aswalls) is needed.

The invention, among other things, represents a recognition that quickand easy reconfiguration of panels on walls can be provided by a clampassembly for attaching the panels to the walls.

The first and second embodiments of the invention, among other things,provide a clamp assembly including a base, a receptacle attached to thebase and a clasp that fits into and attaches to the receptacle. Theclasp has resilient arms and a head. Insertion of the resilient arms ofthe clasp into the receptacle draws the head towards the base, whichproduces a clamping action.

A third embodiment of the invention, among other things, provides achannel having sidewalls attached to a base and at least one fastenerhaving a blade-like shank and a head. The sidewalls converge so as to bemore closely spaced together at the opening to of the channel than atits base. The at least one fastener appears T-shaped in cross section,and is sized such that insertion of the blade-like shank into thechannel widens the opening.

The fourth and fifth embodiments of the invention, among other things,provide a clamp assembly comprising a first clamping piece and a secondclamping piece configured to cooperatively engage each other. The firstclamping piece has a base plate, a first shank attached to extendperpendicularly to the base plate and a first member (of a reclosablefastener pair) attached to the first shank at an end distal to the baseplate. The second clamping piece has a head plate, a second shankattached to extend perpendicularly to said head plate and a secondmember (of the reclosable fastener pair) attached to the second shank atan end distal to the head plate. The base plate and the head plate areparallel when the first member and second member are connected.

In the fourth embodiment, each of the first member and second member isa strip of mushroom-shaped stems. In the fifth embodiment, thereclosable fastener pair is a hook and loop fastener pair.

The foregoing and other objectives of the present invention will becomemore apparent from the detailed description given hereinafter. However,it should be understood that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the invention will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus do not limit ofthe present invention and wherein:

FIG. 1 is a three-quarter perspective view of a first embodiment of aclamp assembly according to the invention;

FIG. 2 is a top view of the receptacle and base according to the firstembodiment;

FIG. 3 is a top view of the clasp according to the first embodiment;

FIG. 4 is a plan view of a plurality of panels attached to the wallusing the clamp assembly according to the first embodiment;

FIG. 5 is a cross-sectional view of a second embodiment, wherein thepull pin is retracted;

FIG. 6 is a partial cross-sectional view of the clasp according to thesecond embodiment, wherein the pull pin is extended;

FIG. 7 is a top view of the clasp according to the second embodiment;

FIG. 8 is a three-quarter perspective view of a third embodiment of aclamp assembly according to the invention;

FIG. 9 is a plan view of the channels, according to the thirdembodiment, attached to a wall;

FIG. 10 is a three-quarter perspective view of a plurality of panelsattached to the wall using the clamp assembly according to the thirdembodiment;

FIG. 11 is a plan view of a plurality of a first type of panels for usewith the first and second embodiments;

FIG. 12 is a plan view of a plurality of a second type of panels for usewith the first and second embodiments;

FIG. 13 is cross-sectional of channel having an alternative arrangementof the sidewalls;

FIG. 14 is a cross-sectional of channel having another alternativearrangement of the sidewalls;

FIG. 15 is a cross-sectional view of a fourth embodiment, wherein thepull pin is retracted;

FIG. 16 is a top view of the fourth embodiment, as well as a fifthembodiment;

FIG. 17 is a cross-sectional view of the fifth embodiment, wherein thepull pin is retracted; and

FIG. 18 is partial plan view of a panel attached to the wall via afastener according to the invention.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION

FIG. 1 is a three-quarter perspective view of a first embodiment of aclamp assembly 100 according to the invention, which includes a lowerclamp structure 104 (represented by a base 110 and a receptacle 112) anda clasp 102 that interlock.

The clasp 102 has resilient arms 106 and a head 108. In cross-section,the head 108 is preferably plano-convex. The resilient arms 106 attachto the planar side of the head 108. The head 108 preferably (but notnecessarily) has a finger grip 120 in the form of a ridge. Thecross-section of the ridge is a compromise betweenfinger-tip-grippablility and smoothness of the upper surface of the head108.

The technology of the interlock between the receptacle 112 and theresilient arms 106 is generally known, for example as disclosed in U.S.Pat. No. 4,150,464 to Tracy et al., patented Apr. 24, 1979, the entiretyof which is hereby incorporated by reference. The resilient arms 106have a raised locking tab 114. A leading edge 116 of the tab 114 isbeveled to promote deflection of the arm 106 toward the other arm 106upon (and in furtherance of) insertion of the clasp 102 into thereceptacle 112. A trailing edge 118 of the tab 114 is beveled to promotedeflection of the arm 106 toward the other arm 106 upon (and infurtherance of) withdrawal of the clasp 102 from the receptacle 112.

The receptacle 112 has narrow sides 122 and wide sides 124. In eachnarrow side 122 is a slot 126. The locking tab 114 fits into the slot126 upon full insertion of the clasp 102 into the receptacle 112.

The head 108 of the clasp 102 and the base 110 are preferably circular,as emphasized in FIGS. 2 and 3, respectively. FIG. 2 is a top view ofthe base 110 and FIG. 3 is a top view of the head 108. Holes 202 areformed to facilitate attaching the base 110 to a substrate 510 (such asa wall) with typical fasteners, such as drywall screws or nails. FIG. 2depicts two holes 202, with one hole on each side of the notch 206. Thenumber and location of holes will depend on the application to which theclamp system 100 is put. Alternatively, the base 110 could be attachedto the wall with an adhesive, or a type of reclosable fastenertechnology such as that discussed in more detail below.

Where four panels meet, space must be made for the arms 106 andreceptacle 112. This is accomplished by removing a triangular or coneshaped portion of the corner of each of panels 404. Four such trianglesor cones define a square or circle of sufficient area to accommodate thearms 106 and the receptacle 112. FIG. 3 depicts cone-shaped cornerportions of the panels 404 as having been removed. FIG. 2 depicts asimilar implementation of the panels, albeit in dashed lines because thepanels overlay the base 110. The area of the head 108 must be largeenough to provide sufficient overlap of the arc-shaped corners 306 sothat adequate clamping force is applied to the panels 404.

FIG. 11 is a plan view of a plurality of panels 1102 which have hadcone-shaped corner portions 1104 removed. FIG. 12 is a plan view of aplurality of panels 1202 which have had triangular corner portions 1204removed.

Preferably, but not necessarily, the base 110 and the head 108 have anotch 206 and 302, respectively, that defines an axis of symmetry. Thereceptacle 112 is positioned entirely on one side of the axis ofsymmetry 206. Similarly, if the optional finger grip 120 is present, itis positioned entirely on one side of the axis of symmetry 302. Thenotches 206 and 302 promote the bending and snapping-off of the unusedportions 208 and 304 of the base 110 and the head 108 along the axes ofsymmetry, respectively. This reduces the capacity of the clamp assemblyfrom four to two panels, as will be discussed in regard to FIG. 4.

FIG. 4 is a plan view of a paneled wall 402 formed of a plurality ofpanels 404 attached to a bare wall (not depicted in FIG. 4 becauseobscured by the panels 404 and the heads 102 and 406) using the clampassembly 100. The full heads 108 are depicted where the corners of fourpanels 404 are adjacent. A half head 406, formed by snapping off theunused portion 208 of the full head 108, is depicted where only twopanels are adjacent. If it were not possible to form a half-head 208(and associated half-lower-clamp structure 104 (not depicted)), then afull head 108 (and associated lower clamp structure 104) would overhangthe edge regions, as denoted by the dashed half circle 408 of FIG. 4.

The clamp assembly 100 is preferably formed of a material that is rigidand that can be injection molded (so that the two pieces of the clampassembly can be integrally formed). Such a material, e.g., is plasticsuch as nylon or delrin. If the panel presents an absorptive surface tothe room, then a clamp assembly made of nylon or delrin will present asmall area of diffusion. However, the area of the head 108 of the clasp102 is typically a few square inches while the area of a typical 2 ft×4ft acoustically-significant panel is 1152 square inches, i.e., adifference of three orders of magnitude. As such, the diffusion causedby the head 108 is considered negligible.

FIG. 5 is a side view of a second embodiment. The second embodimentdiffers from first embodiment by using a pull pin (or movable arm) 504rather than a finger grip 120. For the clasp 502, the pull pin 504 islocated entirely on one side of the axis of symmetry and is movablethrough the head 108 between a first position and a second position. Thefirst position is the fully retracted position wherein the pull pin 504extends from the head 108 towards the distal ends of the resilient arms106. In FIG. 5, a first end 506 and a corresponding recess in the convexsurface of the head 108 cooperate in a first detent arrangement to holdthe pull pin 504 in the first position.

The second position is the fully extended position wherein the pull pinextends from the head 108 in a direction opposite to the direction thatthe resilient arms 106 extend. In the first or fully retracted position,a second end 508 of the pull pin preferably hangs down inside thereceptacle 112. In the second or fully extended position, the second end508 of the pull pin 504 and a second recess cooperate in a second detentarrangement to hold the pull pin 504 in the second position. A user canmove the pull pin 504 from the first position to the second position byprying the first end 506 out of the recess in the convex surface of thehead 108.

FIG. 6 is a partial side view of the clasp 502 according to the secondembodiment, wherein the pull pin 504 is in the second or extendedposition. A user can move the pull pin 504 from the second position tothe first position pushing on the first end 506 until the second end 508disengages from the recess in the planar surface of the head 108. FIG. 7is a top view of the clasp 502 according to the second embodiment.

FIG. 8 is a three-quarter perspective view of a third embodiment of aclamp assembly according to the invention. The clamp assembly 800includes at least one fastener 802 and a channel 804.

The channel 804 has a base 810 and two sidewalls 812 that converge sothat they are more closely spaced together at or near the opening to thechannel than they are at the base 810. In cross-section, the base 810 ispreferably plano-convex, with the sidewalls 812 extending from theconvex surface of the base 810. The plano-convex cross section ispreferred because it provides minimal separation between the panels 404and the bare wall 510.

In FIG. 8, the cross-section of the sidewalls 812 and the portion of thebase 810 therebetween is trapezoidal. Alternatively, the cross-sectionof the sidewalls 1302 and the portion of the base 810 therebetween canbe concave-concave, as in FIG. 13. Also alternatively, the cross-sectionof the sidewalls 1402 and the portion of the base 810 therebetween canbe convex-convex, as in FIG. 14.

The fastener 802 has a blade-like shank 806 and a head 808. Incross-section, the head 808 is plano-convex, with the shank 806extending from the planar surface of the head 808 so that together thehead 808 and the shank 806 appear T-shaped. The width of the blade-likeshank 806 is slightly greater than the width of the opening of thechannel 804 between the sidewalls 812 so that the blade-like shank 806forces the sidewalls 812 apart slightly upon insertion, which causes thesidewalls 812 to grip the blade-like shank 806. To improve the grip onthe blade-like shank 806 by the sidewalls 812, the surface of the shank806 is non-smooth, e.g., ringed.

The width of the head 108 must be large enough to provide sufficientoverlap of the edges of the panels 404 so that that adequate clampingforce is applied to the panels 404.

Preferably, but not necessarily, the fastener 802 includes a finger gripflange 814 attached to the head 808. The flange 814 is preferablybulbous in cross-section, with the larger end of the bulb being disposedaway from the convex surface of the head 808. As such, in cross-section,the fastener 802 having the flange 814 looks like a push-pin.

FIG. 9 is a plan view of a plurality of the channels 804 attached to thebare wall 510. The channels 804 are depicted as being attached to studs910 within the wall 510 via typical fasteners 904, such as drywallscrews or nails, e.g., with a fastener 904 located on either side of thechannel 804, i.e., outside the sidewalls 812. The studs 910 areseparated a uniform distance 916, typically 16 inches from center tocenter. The channels 810 are also uniformly space apart a distance 908,corresponding to a length or width of the panels 404. The channels 804are mounted in essentially the same way as furring strips are mounted.

Like the heads 108 of the first and second embodiments, the head 808 ofthe third embodiment presents a small area of diffusion, which can beinconsistent with a goal of attaching panels having an absorptivesurface. Again, however, the area of the head 808 is much smaller thanthe area of a typically-sized panel 404, so that the diffusion caused bythe head 808 is considered negligible.

FIG. 10 is a three-quarter perspective view of a plurality of panels 404attached to a bare wall (not depicted in FIG. 10 because obscured by thepanels 404 and the heads 808) using the clamp assembly 800 according tothe third embodiment. Because it is not easy to form a half-head (as inthe first and second embodiments), a full head 808 overhangs the edgeregions, examples of which are denoted by arrows 1004. Examples of headscovering the corners of four panels are denoted by arrows 1002.

FIG. 15 is a cross-sectional view of a fourth embodiment of a clampassembly according to the invention. The fourth embodiment is similar tothe first and second embodiments. In FIG. 15, the resilient arms 106 andthe receptacle 112 of FIG. 1 have been replaced by a first part 1502 anda second part 1504. The first part 1502 includes a first shank 1506connected to the planar side of the head 108. Attached to an end of thefirst shank 1506, that is distal to the head 108, is a strip 1508 ofmushroom-shaped stems. The second part 1504 includes a second shank 1510connected to the planar side of the base 110. Attached to an end of thesecond shank 1510, that is distal to the base 110, is another strip 1508of mushroom-shaped stems. The first part 1502 and the second part 1504can be split in half, e.g., like the first and second embodiments.

The two strips 1508 of mushroom-shaped stems together form reclosablefastener pair. Such reclosable fastener technology is known, e.g., asmarketed by the 3M Corporation under the trade name of the Dual LockIndustrial Fastener.

The pair of mushroom-shaped stem strips provide a rigid, strongconnection when the mushroom-shaped stems are pushed together to thepoint that they interlock. This connection also provides torsionalstability. Thus, the fourth embodiment shares these qualities with thefirst to third embodiments. However, the fourth embodiment is slightlydifferent in that it provides less alignment than is inherent to thefirst to third embodiments.

In FIG. 15, the pull pin 504 is depicted as being retracted. FIG. 16 isa top view of the fourth embodiment, as well as a fifth embodiment. Theretracted pull pin 504 fits into a void 1602 in the first shank 1506.The first shank 1506 (and therefore the second shank 1510) is depictedas being circular in cross-section, but any shape can be used.

FIG. 15 also depicts an alternative way to configure panels that areattached by the clamp systems according to the invention. In FIG. 16,only the panels 404 are notched. The panels 1604 do not need to benotched at the corners because the first shank 506 is formed to one sideof the line 206 of symmetry.

FIG. 17 is a cross-sectional view of the fifth embodiment of a clampassembly according to the invention. FIG. 17 is similar to FIG. 15,except that the strips 1508 of mushroom-shaped stems have been replacedby a hook and loop fastener pair 1706, which defines a new first part1702 and a new second part 1704.

The first part 1702 has a strip 1710 of loops attached to the end of thefirst shank 1506 that is distal to the head 108. The second part 1704has a strip of hooks attached to the end of the second shank 1510. Suchhook and loop reclosable fastener technology is known, e.g., as marketedby the 3M Corporation under the trade name of the Scotchmate IndustrialFastener.

As in FIG. 15, the pull pin 504 is depicted in FIG. 17 as beingretracted. As noted above, FIG. 16 is a top view of the first part 1702of FIG. 17 as well as the first part 1502 of FIG. 15.

FIG. 18 is partial plan view of a panel attached in a different way to awall via a fastener according to the invention. In FIG. 18, a panel 1804is attached to a wall (not shown) via a clamp assembly, of which thehead 1802 is depicted. Any of the clamp assemblies according to theinvention can be used. The panel 1804 has an aperture 1808 through whichcan pass a portion 1806 (corresponding to a shank, blade-like shank,resilient arms, etc.). The aperture can be located anywhere in the panel1804, e.g., in the center.

Thus, the invention, among other things, provides a quick and easytechnology for attaching, and facilitating reconfiguration (detachingand reattaching) of, panels to walls.

The invention being thus described, it will be obvious that the same maybe varied in many ways. Such variations are not to be regarded as adeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are intendedto be included within the scope of the following claims.

What is claimed is:
 1. A clamp assembly comprising: a first clampingpiece; and a second clamping piece configured to cooperatively engagesaid first clamping piece; said first clamping piece including a baseplate, a first shank attached to extend perpendicularly to said baseplate, and a first member, of a reclosable fastener pair, attached tosaid first shank at an end distal to said base plate; said secondclamping piece including a head plate, a second shank attached to extendperpendicularly to said head plate, and a second member, of saidreclosable fastener pair, attached to said second shank at an end distalto said head plate; wherein said base plate and said head plate areparallel when said first member and second member are connected.
 2. Theclamp assembly of claim 1, wherein each of said first member and saidsecond member is a strip of mushroom-shaped stems.
 3. The clamp assemblyof claim 2, wherein said reclosable fastener pair is a hook and loopfastener pair.
 4. The claim assembly of claim 1, wherein each of saidfirst clamping piece and said second clamping piece are integrallyformed.
 5. The clamp assembly of claim 1, wherein said first clampingpiece and said second clamping piece are cooperatively engaged andcharacterized by a line of symmetry, said first shank and said secondshank being positioned to a same side of said lines of symmetry,respectively.
 6. The clamp assembly of claim 5, wherein an upper surfaceof said head plate is notched along said line of symmetry to promotedetachment of a portion of said head plate opposite to a portion of saidhead to which said second shank is attached.
 7. The clamp assembly ofclaim 5, wherein said base plate has at least two holes for attachmentto a substrate.
 8. The clamp assembly of claim 7, wherein said at leasttwo holes are located on opposite sides of said line of symmetry.
 9. Theclamp assembly of claim 6, wherein said head plate includes a fingergrip flange on the same side of said line of symmetry as said secondshank.
 10. The clamp assembly of claim 6, wherein said first clampingpiece has a movable arm on the same side of said line of symmetry assaid second shank, said movable arm being movable through said headplate between a first position for storing said arm and a secondposition for making said movable arm available as a finger grip.
 11. Theclamp assembly of claim 10, wherein said first position disposes saidmovable arm, to extend from said head plate toward a distal end of saidsecond shank and said second position disposes said movable arm toextend from said head plate in a direction opposite to which said secondshank extends.
 12. The clamp assembly of claim 10, wherein said movablearm maintains said first position via a first detent arrangement withsaid head plate and said movable arm maintains said second position viaa second detent arrangement with said head plate.
 13. The clamp assemblyof claim 1, wherein said head plate is plano-convex in cross-section.